Toyota2011–2012

Hilux 2.5 D-4D: Common faults & known problems

Common faults & known problems

17 known faults documented in workshop bulletins. Of these, eight concern the engine and fuel system and four the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

8 documented faults — symptoms, causes and workshop fixes.

Lack of power

Overview

Affects: All models with 2KD-FTV engine code.
Fault codes: P0088P0093
Parts: 1 part

Symptoms

Black smoke from exhaust. Engine speed will not increase above 1000rpm. Engine stalls. Possible trouble codes: P0088, P0093.

Cause

Fuel pump (FP) sticking.

Repair

Replace fuel pump (FP)A.
Secure fuel pump (FP) wiring harnessB.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Fuel pump (FP)	22100-30090	1

Data: Motorwise Workshop. Bulletin 1.

Engine difficult to start

Affects All models with 2KD-FTV engine code without turbocharger (TC) intercooler.Software update

Cause

Engine control module (ECM) software fault.

Repair

Install upgraded engine control module (ECM) software.

Data: Motorwise Workshop. Bulletin 3.

Poor engine performance

Affects All models with Diesel engines.P2121

Symptoms

Trouble code stored in engine control module (ECM) fault memory: P2121.

Cause

Internal failure of accelerator pedal position (APP) sensor.

Repair

Replace APP sensor.

Data: Motorwise Workshop. Bulletin 5.

Engine malfunction indicator lamp (MIL) illuminated. Trouble code stored: P0069

Affects All models with Diesel engines.P0069Fit new part

Cause

Manifold absolute pressure (MAP) sensor faulty or contaminated with dirt.

Repair

Fit new MAP sensor.

Data: Motorwise Workshop. Bulletin 11.

Engine runs in limp home mode

Affects All models with Diesel engines.P0046P2564Fit new part

Symptoms

Trouble codes stored in engine control module (ECM) fault memory: P0046, P2564.

Cause

Turbocharger (TC) control solenoid faulty.

Repair

Fit new turbocharger (TC) control solenoid.

Data: Motorwise Workshop. Bulletin 13.

Rattling noise from engine when idling

Affects All models with Diesel engines.Clean & lubricate

Symptoms

Various trouble codes related to EGR system stored in engine control module (ECM) fault memory.

Cause

Carbon deposit build up in intake manifold.

Repair

Clean carbon deposits from intake manifold.

Data: Motorwise Workshop. Bulletin 14.

Excessive black smoke from exhaust

Affects All models with Diesel engines.

Symptoms

Poor engine performance.

Cause

Poor sealing of fuel injectors allowing blow-by gas.

Repair

Renew fuel injector sealing washer.

Data: Motorwise Workshop. Bulletin 15.

Engine malfunction indicator lamp (MIL) illuminated. Possible trouble codes stored: P0671, P0672, P0673, P0674

Affects All models with 4-cylinder Diesel engine, →10/14.P0671P0672P0673P0674Fit new part

Cause

Defective glow plugs.

Repair

Fit new glow plugs.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Glow plug	19850-30030, or 19850-30040	4

Data: Motorwise Workshop. Bulletin 17.

Brakes

4 documented faults — symptoms, causes and workshop fixes.

Knocking noise from brake pedal area when driving over rough roads

Affects All models.Fit modified part

Cause

Excessive free play between brake pedal and brake servo clevis joint.

Repair

Fit modified brake servo clevis joint.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Clevis joint	47264-26030	1

Data: Motorwise Workshop. Bulletin 4.

Excessive front brake wear

Affects All models.

Cause

Brake load proportioning valve incorrectly adjusted causing increased wear to front brakes.

Repair

Check and adjust brake load proportioning valve.

Data: Motorwise Workshop. Bulletin 8.

ABS warning lamp illuminated

Overview

Affects: All models with ABS.
Fault codes: C0274

Symptoms

Trouble code stored in ABS control module fault memory: C0274.

Cause

Faulty ABS control module.

Repair

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Replace ABS control module.

Data: Motorwise Workshop. Bulletin 12.

ABS warning lamp illuminated. Trouble code(s) related to front ABS wheel speed sensor(s) stored in fault memory

Affects All models.

Cause

Front ABS wheel speed sensor wiring harness damaged.

Repair

Check for open circuit/high resistance in wiring harness between front ABS wheel speed sensor and ABS control module. Repair/replace component(s) as necessary.

Data: Motorwise Workshop. Bulletin 16.

Steering

1 documented fault — symptoms, causes and workshop fixes.

SRS warning lamp illuminated

Affects All models.B1801Fit new part

Symptoms

Trouble code stored in SRS control module fault memory: B1801.

Cause

Steering wheel spiral cable faulty.

Repair

Fit new steering wheel spiral cable.

Data: Motorwise Workshop. Bulletin 7.

Clutch & gearbox

1 documented fault — symptoms, causes and workshop fixes.

Air conditioning (AC) inefficient

Affects All models with air conditioning (AC).

Cause

AC compressor clutch relay faulty.

Repair

Replace AC compressor clutch relay.

Data: Motorwise Workshop. Bulletin 6.

Air conditioning & heating

2 documented faults — symptoms, causes and workshop fixes.

Low heater output

Sand particles in engine coolant causing thermostat to stick open.

Overview

Affects: All models with 2KD-FTV engine code (→engine No.7203753).

Symptoms

Failure of engine to reach normal operating temperature.

Repair steps

Drain cooling system.
Remove thermostat.
Rinse cooling system with water.
Renew thermostat and seal.
Fill cooling system.

Data: Motorwise Workshop. Bulletin 2.

Engine runs in limp home mode

Affects All models with Diesel engines.P2008Fit new part

Symptoms

Trouble code stored in engine control module (ECM) fault memory: P2008.

Cause

Intake manifold air control solenoid faulty.

Repair

Fit new intake manifold air control solenoid.

Data: Motorwise Workshop. Bulletin 9.

Wipers & visibility

1 documented fault — symptoms, causes and workshop fixes.

Windscreen wipers intermittent wipe function not working

Affects All models.

Cause

Internal failure of combination switch.

Repair

Replace combination switch.

Data: Motorwise Workshop. Bulletin 10.

Glossary

Technical terms used in this guide.

ECM: Engine control module — the electronic unit that manages the engine
ABS: Anti-lock braking system — stops the wheels locking under hard braking
EGR: Exhaust gas recirculation — feeds some exhaust gas back into the intake to cut emissions
Brake Servo: The unit that boosts the force of your foot on the brake pedal
Trouble Codes: Standardised fault codes stored by the engine control module, read with a diagnostic tool
AC: Air conditioning — the system that cools the cabin
FP: Fuel pump — the pump that supplies fuel from the tank
SRS: Supplementary restraint system — the airbags and seat-belt pretensioners
TC: Turbocharger — the exhaust-driven compressor that boosts engine power
Accelerator Pedal Position: The sensor that tells the engine control module how far the accelerator is pressed
Control Module: A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
Fault Memory: The list of stored trouble codes in a control module
Glow Plugs: Heaters that help a diesel engine start from cold
Intake Manifold: The housing that distributes air into the cylinders
Intercooler: A radiator that cools the air coming out of the turbocharger before it enters the engine
Manifold Absolute Pressure: A sensor reading of pressure in the intake — used to work out engine load
Relay: An electrically operated switch
Solenoid: An electrically operated valve or actuator
Trouble Code: A standardised fault code stored by a control module, read with a diagnostic tool
Wheel Speed Sensor: A sensor at each wheel used by ABS and stability control
Wiring Harness: The bundled cables that carry power and signals around the vehicle

Frequently asked questions

What are the common faults with the Toyota Hilux 2.5 D-4D?

This guide contains 17 workshop bulletins for the Toyota Hilux 2.5 D-4D. Of these, eight concern the engine and fuel system and four the brakes. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Toyota Hilux 2.5 D-4D have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Toyota Hilux 2.5 D-4D faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.